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Dewalt Table Saw Fence (Rack & Pinion) problem...

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Forum topic by BGW posted 09-23-2014 02:52 PM 17785 views 0 times favorited 18 replies Add to Favorites Watch
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BGW

165 posts in 1844 days


09-23-2014 02:52 PM

Friends,

I am appealing to you all for some help with my Dewalt DW745 table saw. As some of you know, this saw boasts a rack & pinion fence system that is supposed to be easy to use and accurate. When I first bought mine, never slid softly like it’s supposed to, but it didn’t matte that much to me, because I was able to move it.

Over the past year, as I’ve used and abused it, the rack and pinion gears have become more and more tight…now they completely bindup and I’m virtually unable to move it at all.

Has anyone else had this issue, and if so…how did you rectify it?

-- Bob, Indiana, "Well done is better than well said." -Ben Franklin http://www.bgwconstructionllc.com/


18 replies so far

View paxorion's profile

paxorion

1107 posts in 1883 days


#1 posted 09-23-2014 03:10 PM

Are the gears thrown out of alignment by chance? Any suggestions from Dewalt support?

-- paxorion

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BGW

165 posts in 1844 days


#2 posted 09-23-2014 04:32 PM

I’m sure that’s what it is, I just can’t get them re-aligned…

-- Bob, Indiana, "Well done is better than well said." -Ben Franklin http://www.bgwconstructionllc.com/

View gabriellus's profile

gabriellus

47 posts in 1215 days


#3 posted 09-23-2014 05:44 PM

I have the DWE7491RS with the similar rack and pinion fence. I recently had to entirely disassemble the fence and rail system as the rail was just crazily bogged down, the handle was just impossible to twist. After taking it apart, it was clear it was the rails themselves taking in chips and dust and getting gummed up. I’ve cut mostly pine, you see. Next time I’ll add some teflon spray that I bought since I reassembled, I bet that will help. The rack and pinion part was fine, but you WILL need to realign/adjust the fence when you get it all back together.

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BGW

165 posts in 1844 days


#4 posted 09-23-2014 06:08 PM

Thanks, Gabriellus…that’s what I was thinking about doing, but I wanted to see if anyone had the same experience. We use it a lot with PT material, so I imagine there is quite a bit of gumming going on.

-- Bob, Indiana, "Well done is better than well said." -Ben Franklin http://www.bgwconstructionllc.com/

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gabriellus

47 posts in 1215 days


#5 posted 09-24-2014 06:45 PM

Not a problem, glad to help!

As a side note, your post got me thinking to do that work. Having now taken it apart for a second time, I noticed that in my case, the most problematic area in the rail assembly was the contacts of what Dewalt calls the Rail Lock. When you lock the fence in position, you push down a lever which in turn pushes out a metal pin against inside the front and rear rail, locking it in place. It seemed like in the unlocked position, the pin was still too far out, binding up the rail. In any case, disassembling everything and hitting all sides of the rail/gear/teeth/runners pretty hard with this seemed to get me back to near factory condition.

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gabriellus

47 posts in 1215 days


#6 posted 01-08-2015 07:21 PM

I thought I’d repost with an update. Just performed the Rail Lock Adjustment (page 7 Fig 17 in the DWE7491RS manual). In order to loosen the jam nut (JJ) I needed locking pliers and a great deal of force. Once loosened, I adjusted the hex rod (KK) to the loosest it would go and still lock the fence snugly, which in my case seems a great deal indeed. After that it has been a dream, no binding in any way whatsover.

View htl's profile (online now)

htl

3154 posts in 997 days


#7 posted 06-12-2017 02:36 AM

Old post but thought I’d add that if you turn it upside down once in a while and blow it all out then brush any gummed up teeth and while your at it give the rest of the saw a look over and scrape all the packed up wood between the gears, you’ll have a new saw.
Don’t wait till it starts giving you trouble.

-- There's a hundred ways to do anything, alot depends on the tools at hand.

View Carlyfaye's profile

Carlyfaye

3 posts in 105 days


#8 posted 09-01-2017 04:22 AM

I am having the same problem with my DeWalt table saw. It worked like butter when I got it a couple of years ago and gradually got tighter and tighter, and now is totally frozen. I am going to try to break it down and clean it up. I just wish I could find a video that shows exactly how to do it. This post has been very helpful. Thank you.

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htl

3154 posts in 997 days


#9 posted 09-01-2017 10:09 AM

Carlyfaye You don’t need to break it down to clean up the gummed up teeth on the fence, just lower the blade and lay it upside down flat on a table and once you start looking around you’ll see the wood packed up on the teeth of the fence and around the gears as you try to raise and lower the blade.
It goes with out saying UNPLUG the saw.
I used a stiff brush and a screw driver to clean the gummed up teeth, once cleaned up get some paste wax and rub every thing to keep thing running smooth.
There really aren’t that many parts to this saw and they’re all out in the open once flipped upside down.

Do a search on google for reviews of this saw to get an idea of what the under neath looks like.

-- There's a hundred ways to do anything, alot depends on the tools at hand.

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Carlyfaye

3 posts in 105 days


#10 posted 09-25-2017 01:57 PM

Update on my fence problem. I checked it out and it was clean as a whistle asI use the air compressor to blow sawdust off, but I did notice my knob was busted (probably from trying so hard to turn to adjust fence). I ordered a new knob and installed with no improvement. Next I noticed there was a skid mark ffrom the lock position rod. I loosened that up and problem solved. Not sure how it got in that position in the first place, but we are back in business. Thanks for all the help.

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htl

3154 posts in 997 days


#11 posted 09-25-2017 03:57 PM

Thanks for the come back, it’s always interesting to find out what the problem really was and the fix.

-- There's a hundred ways to do anything, alot depends on the tools at hand.

View scrubs's profile

scrubs

44 posts in 98 days


#12 posted 09-26-2017 05:54 PM



Update on my fence problem. I checked it out and it was clean as a whistle asI use the air compressor to blow sawdust off, but I did notice my knob was busted (probably from trying so hard to turn to adjust fence). I ordered a new knob and installed with no improvement. Next I noticed there was a skid mark ffrom the lock position rod. I loosened that up and problem solved. Not sure how it got in that position in the first place, but we are back in business. Thanks for all the help.

- Carlyfaye

Same thing happened to me. There’s some hardware that holds that lock assembly in place. I actually lost a bolt in mine and my brake would never fully disengage. Once I figured that out (after quite a bit of frustration!) it was fine. :)

Great little saw, I should have kept it.

-- It all seems like a good idea at some point...

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htl

3154 posts in 997 days


#13 posted 09-26-2017 07:08 PM

I wish I could find a died Dewalt saw would love to put that fence on a Shop Smith, maybe one will come along.
Hint Hint any one got a dead one near Alabama. LOL

-- There's a hundred ways to do anything, alot depends on the tools at hand.

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Carlyfaye

3 posts in 105 days


#14 posted 09-26-2017 08:42 PM

I sure wish I had taken the time to figure out the problem a lot sooner. I know what you mean about frustration. I’m also afraid it sustained some damage as it rolls along just fine then it hits a little rough spot. It’s barely noticeable, but hurts my heart just the same.

View BRAVOGOLFTANGO's profile

BRAVOGOLFTANGO

281 posts in 1841 days


#15 posted 11-01-2017 06:20 PM

This was a very helpful post, I’m glad I didn’t need to tear down the rack & pinion system to clean it, it was simply gummed gears and primarily the minor lock-pressure adjustment, works like new again.

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